sf engineering systems (india) pvt ltd statement for sf post ... sf engineering systems (india) pvt...

Method Statement for SF Post Tensioning System (SFEC/WP/01)

1SF ENGINEERING SYSTEMS (INDIA) PVT LTD

SF ENGINEERING SYSTEMS (INDIA) PVT LTDPROJECT :

REVISION :

DATE :

Checked by : Approved by :

Mr. S. Durai Pandian(Executive Director)




REVISION :

DATE :






REVISION :

DATE :





SF ENGINEERING SYSTEMS (INDIA) PVT LTDMETHOD STATEMENT

CONTENTS

1 General 3

2 Scope of Work 3

3 References 3

4 Design data 4

5 Handling and storage of materials 4

6 General work procedure 5

7 Installation Procedure 5

8 Stressing Procedures 7

9 Grouting Procedure 12

Annexure 1 P.T Work Sequence- flowchart 16

Annexure 2 P.T Components and Equipments 21

Annexure 3 Checklist 28

Annexure 4 Admixture 32

Annexure 5 Safety 35

Annexure 6 Quality Assurance Policy (QAP) 39




CONTENTS

1 General 3

2 Scope of Work 3

3 References 3

4 Design data 4















CONTENTS

1 General 3

2 Scope of Work 3

3 References 3

4 Design data 4














1. General:

SF Post Tensioning Systems are developed and maintained by SF

Engineering Systems (India) Pvt Ltd.

Our systems comply with international specifications and recommendations

e.g. BS, EUROCODE, FIP, IS CODE, etc. The quality of SF products and

services is in full compliance with the above.

This method statement has been developed to provide a clear guidance for

all individuals involved in the project in using SF systems which covers the

installation, stressing and grouting activity.

2. Scope of work:

a) Supply of required Pre stressing components like anchorage head, Wedge

Plates, Sheathing, Wedges and miscellaneous materials as per the

specification.

b) Assembling of tendon units in the Post Tensioning slab

according to the drawings provided.

c) Supplying necessary hydraulic jacks & stressing all the

tendons to the required pressure

d) Supplying the grout pump & complete grouting all the tendons.

e) To verify the quality of Pre stressing components delivered

to site & ensure that the entire process is done as per the

specification.

3. References:

Drawing no

Design Report

Prestressing notes and procedure.

Codal provision (IS 1343: 2012 , IS 456 : 2000, BS 8110)



1. General:









2. Scope of work:



specification.








specification.

3. References:

Drawing no

Design Report





1. General:









2. Scope of work:



specification.








specification.

3. References:

Drawing no

Design Report





4. Design data:

Coefficient of Friction (µ) 0.2 (As per Consultant Requirement)

Wobble Factor (k) 0.0017 / m

Draw in wedge 6mm

Stressing Anchorage Flat Anchorage , Multi Anchorage

Loss in Jack 2% (Varies from 0 – 2)

5. Handling and storage of materials:

a) The pre-stressing strands shall be free of grease and corrosion enhancing

materials.

b) No flame cutting of strands is allowed.

c) Care should be taken in the handling of strands in order to avoid

mechanical damage to the strands.

d) Strands should be raised above ground to avoid contamination.

e) Webbing slings shall be used for loading and unloading in order to avoid

mechanical damage to the strand coils.

f) All Post Tensioning components must be handled and stored such that any

contamination, mechanical damage or corrosion can be avoided.



4. Design data:



Draw in wedge 6mm





materials.











4. Design data:



Draw in wedge 6mm





materials.











6. General Work Procedures:

6.1 Pre requisite for commencement of P.T Activity:

a) Shuttering work for the intended P.T slab to be casted

has to be made ready in all respect.

b) Bottom layer of the slab reinforcement & perimeter RCC

beam reinforcement has to be in place / fabricated in

accordance with the approved drawing.

c) Required numbers of pre fabricated bar chairs &

bursting links should be made available

6.2 Preparation:

a) H.T Strand will be uncoiled using coil dispenser.

b) Ensure the straightness of the strand and cut the

strand as per the required length using disc Cutter /

cutting Wheel.

7. Installation Procedures:

For PT Slab Tendons:

Mark the anchorage position onto the reinforcement links / bottom

shuttering as per the approved tendon profile drawing.

Secure the anchorage head (pre assembled with recess former) either by

placing of horizontal support bars across the links (if required) or by tying

directly to the top reinforcement bars of perimeter RCC beam.

Lay the empty GI sheathing in one direction and joint them with the

couplers & connect the same with the anchorage head to form a tendon.

Care should be taken to avoid other trade laborers stepping on to the

empty sheathing laid / formed tendons.












6.2 Preparation:




cutting Wheel.























6.2 Preparation:




cutting Wheel.














Inserting in / threading of strands into the empty sheathing will be

commenced.

Ensure enough stressing length (400mm) of strand has been allowed to

protrude outside the perimeter RCC beam.

Make bulb on to the other end of the strand to form as the dead end of

the tendon.

Mark the profile of the other direction tendons at the crossover points

either on the shuttering / upon the tendon already laid.

Lay the empty GI sheathing in other direction and joint them with the


Ensure the layer of tendons as per the profile drawing is achieved on site.

Seal off all the coupler joints of sheathing laid with the help of OPP tape to

ensure the cement slurry shall not ingresses through these joints.

As per the approved tendon profile drawing, elevate the assembled

tendons to the required height with the help of the bar chairs & secure

them with the binding wires.

Spread the bulb formed strands at the dead end to have 450mm in width

& tie them on to a horizontal bar resting on the required profile bar chair.

Erect the side shuttering with holes for protruding strands & complete the

same to receive concrete.

For PT Beam Tendons:

Install bottom reinforcements, side reinforcements and shear links. But no

capping links shall be installed till the commencement of tendon

installation.

Install tendons in accordance with the shop drawings.

Install top reinforcements and capping links of the beam.




commenced.




the tendon.


















installation.






commenced.




the tendon.


















installation.





7.1 Tolerance:

Vertical Tendon Profile ± 5mm (For High and Low Points)

Horizontal Tendon Profile ± 150mm (To avoid M& E openings)

Note:

Designer shall be consulted for tolerance more than ± 150mm.

7.2 Points to be taken care while Concreting:

Care should be taken to ensure that the sheathing does not get

damaged during concreting.

All the strands projecting outside the slab will be covered with an

empty short sheathing to protect it from the spilled concrete falling on

to it.

Ensure the minimum grade of concrete for Post – Tensioning work

should be M – 35.

8. Stressing Procedures:

Stressing shall not commence unless the main contractor has confirmed the

member has achieved its minimum cube strength at transfer stage.

Compressive strength required for commencing the stressing activity shall be

minimum 27N/mm2 for M – 35 grade of concrete (75 % of fck is required).

8.1 Preparation of Stressing:

Immediately after the removal of side shuttering, the recess former

shall be removed.

The strands projecting outside the anchorages will be cleaned and the

anchor block along with the wedges shall be slotted on to them.



7.1 Tolerance:



Note:







to it.


should be M – 35.








shall be removed.





7.1 Tolerance:



Note:







to it.


should be M – 35.








shall be removed.





Wedges shall be mildly rammed with a steel pipe to ensure for their

even seating.

8.2 Pre requisite for Stressing:

Jacks used for stressing should be supplied with necessary calibration

certificate.

All stressing equipments will be cleaned and checked before put into

operation.

Theoretical elongation calculation shall be prepared and put forwarded

to the consultants review & kept ready.

Compressive strength of concrete should be confirmed to have

achieved 27N/mm2

8.3 Sequence of Stressing:

For Flat Anchorage (FA) System

Each strand in the tendon shall be stressed to 25% of the jacking force

and the datum shall be marked.

The stressing jack has to be inserted back to its position and each

strand has to be stressed for its final pressure.

The elongation for each strand will be checked by measuring the mark

datum.

Measure the distance of the datum mark to the wedge plate. This will

reflect the strand’s elongation from 25% to 100% force. ( assume X

mm )

Add the wedge draw-in of 6mm to the X.

Effective strand’s elongation from 25% to 100% stressing force, Y

Y = X + 6mm (Wedge Draw in)




even seating.



certificate.


operation.




achieved 27N/mm2








datum.



mm )







even seating.



certificate.


operation.




achieved 27N/mm2








datum.



mm )






The total elongation (from 0% to 100% force) shall be calculated by

extrapolation of the value Y.

Total elongation = (Y / 75) X 100

The value will be recorded & documented duly signed by P.T Engineer

/ Clients / Consultants.

Strands will be cut after 24 hrs from completion of stressing activity.

Strand protruding beyond the wedge will be cut 2 times the diameter

of the strand or 25mm away from wedge face using cutting wheel.

For Multiplane Anchorage (MA) System

The multistrand jack shall be secured and hoisted to the anchorage’s

level by chain blocks or crane.

All strands shall be inserted through the jack’s guide pipes.

Connect jack to hydraulic pump.

At the beginning of stressing the strands are locked in the jack pulling

head.

The pressure readings and the measured elongation are recorded in

the stressing report.

Stress initially to 10Mpa to remove slack in the strands.

Proceed stressing and record the strands’ elongation for every

incremental of 10MPa pressure.

When the jack has reached the end of its stroke or the desired force

has been obtained, the pressure in the jack is released and the strands

will locked uniformly by the wedges in the wedge plate.

The jack piston returns.

Stressing is continued in as many stages as are necessary to obtain

the required forces.

Note: De-Shuttering at pour strip area can be carried out after completion of

concreting in that area and after achievement of required compressive strength.

















head.






























head.
















SAMPLE JACKING FORCE CALCULATION

UTS of Strand=183.7 KN (for 0.5” Strand)

260.7 KN (for 0.6” Strand)

Jack Loss = 2%

= 1+ 2 = 1.02

100

Applying force = 75% of UTS

Ram Area of SF T-25 Jack = 3300 mm2 (or) 33cm2

Formula

Jacking force = Pressure X Jack Loss

Area

(Nos of Strands X UTS X 75% X Jack Loss)/Jack Ram Area

Jacking force = (1x183.7 x 100) x 75% x 1.02 = 425.85 Kg/cm2

(For 0.5” Strand) 33



Note:

The Jacking force value may change depending upon the type of Hydraulic Jack and

its Ram Area used at site.






Jack Loss = 2%

= 1+ 2 = 1.02

100



Formula


Area






Note:








Jack Loss = 2%

= 1+ 2 = 1.02

100



Formula


Area






Note:





INTERPRETATION OF STRESSING RESULTS

Note:

(P) The Engineer shall be informed and consulted for more investigation and design

check

Check Elongation (X) forindividual Tendon

Within ±8%

ok

Average deviationper pour/over beamsection within ±8%

ok




Note:


check

Check Elongation (X) forindividual Tendon

Not Within± 8%

X< -8%

Average deviationper pour/over beamsection within ±8%

Average deviationper pour/over beam

section < 8%

stress the tendon with X<-8%to max of 80% UTS

Average deviation perpour/over beam

section within ± 8%

ok


section< 8%

See (P)

Average deviationper pour/ overbeam sectionwithin ±8%

ok




Note:


check


section< 8%

X> +8%

Average deviationper pour/ overbeam sectionwithin ±8%

ok

Averagedeviation per

pour/over beamsection > 8%

Hold thefinal

pressure for15 sec

admin

Typewritten text

Project : Location: Date: Sheet: 1 of 2

admin

Typewritten text

Project : Location: Date: Sheet: 2 of 2



9. Grouting Procedures:

After the stressing and trimming of strands are completed, sealing of

tendons recesses will be done using cement mortar as per specifications.

Water will be potable, free from impurities and cement (OPC – 53 grade)

will be used and the same should be free from any lumps.

Water and cement will be mixed as per the details given in the Codal

specification using mixer and agitate the mix continuously.

The W/c ratio will be kept as 0.45 and mixing time of grout will be 2 – 3

minutes and approved non-aluminum based expanding agent may be

added as per Codal specifications.

Grout in the collection drum will be kept in continuous slow agitation by

means of agitator until pumped into the duct.

Grout will be pumped into the duct by inlet.

Start filling the duct with the specified grout mix, consistency of the grout

has to be checked from the other end grout vent, and if it reaches the

same, close both the vent. Build the grout pressure from 3 to 5kg/cm2

and maintain the pressure for 15- 20 seconds and seal the other end by

tying with binding wire.

The inlet will be closed and pressure will be released from grout pump by

releasing the return valve in the grout pump.

Same procedure will be adopted for remaining cables.

During grouting workers will wear protective goggles, helmets, and hand

gloves.

All the data will be recorded in the format.

























gloves.


























gloves.




GROUT MIX

Cement = Ordinary Portland Cement (53 – grade) 50 Kg

Water = 0.45 x 50Kg (Per bag of cement) = 22.5 litres

Per Batch = 3 bags of cement

Admixture = Conplast P 211M (Fosroc) 0.2% weight of cement (50Kg)

Cebex 100 (Fosroc) 225g per bag of cement (50Kg)

Mixing Sequence = Water – Cement – Admixture

Mixing Time =2 – 3 min

a) For Conplast P 211 M: (Refer Annexure – 4)

Cement Required = 3 bags (150 Kg)

Water Required for 3 bags of cement = 68 litres

Admixture Required for 3 bags of cement = 300ml

b) For Cebex 100: (Refer Annexure – 4)



Admixture Required for 3 bags of cement = 675g



GROUT MIX


















GROUT MIX


















9.1 Tests for Grouting:

Viscosity Test

Compressive Strength

Viscosity Test:

Viscosity test will be executed by means of a flow cone.

Flow time is measured with a stop watch.

It is the measurement of time that the grout takes to completely

flow out of the cone.

It is carried out after the 2-3 min minimum mixing time.

The flow time should be between 10 to 25 seconds.




Viscosity Test


Viscosity Test:










Viscosity Test


Viscosity Test:









Compressive Strength:

6 test cubes of 100 x 100 x 100 mm shall be prepared per groutingsession.

After 24 hours, remove cubes from mould and store in the waterstorage tank.

Compressive strength at 7 and 28 days for 3 cubes each shall betested.

According to specification, average compressive strength of 3 cubes shall be as

follows:

7 - Days 17 N/mm2

28 - Days 30 N/mm2








follows:

7 - Days 17 N/mm2

28 - Days 30 N/mm2








follows:

7 - Days 17 N/mm2

28 - Days 30 N/mm2



ANNEXURE – 1

P.T WORK SEQUENCE – FLOW CHART



ANNEXURE – 1




ANNEXURE – 1




Post - Tensioning

Laying



Post - Tensioning

Stressing Grouting



Grouting



Laying

BottomShuttering

Bottom Rebar



Bottom Rebar

Installation ofduct with HT

Strands

Fixing of castingand joining with

duct

Wrapping ofduct joints with

opp tape

Profile chairfixing

Top Rebar

Casting themember



Top Rebar

Casting themember



Stressing

Removal of sideShuttering andrecess former

Fixing of wedge plateand wedges



Removal of sideShuttering andrecess former

Fixing of wedge plateand wedges

Insertion of jack tothe strands in

position

Initial pressure25% for slack

removal

Initial marking ofstrand with

marker

Final pressure asper specification

Checking theelongation and

recording the values

Chopping of protrudingstrand after 24 hours



Final pressure asper specification

Checking theelongation and

recording the values

Chopping of protrudingstrand after 24 hours





Grouting

Patching therecess pocket with

cement mortar

After 48 hourpreparation of

grouting activity

Mixing (Cement +Water + Additive)

Mixing thecomponents in

grout pump for 3 -5 Min

Inject the groutthrough the grout

inlet

Flow of groutthrough outlet

with sameconsistency

Lock the outletand withold

pressure for 3 - 5bars for 15 sec

Adopt sameprocedure for

remaining tendons





ANNEXURE – 2

P.T COMPONENTS & EQUIPMENTS



ANNEXURE – 2




ANNEXURE – 2




Strands:

Strands 0.50” 0.60”

Nominal Diameter 12.7mm 15.24mm

Nominal Area 100mm2 140mm2

Nominal Weight 0.785kg/m 1.102kg/m

Tensile Strength 1860N/mm2 1860N/mm2

Modulus of elasticity 195kN/mm2 195kN/mm2

Min breaking load 183.7kN 260.7kN



Strands:

Strands 0.50” 0.60”









Strands:

Strands 0.50” 0.60”









GI - Duct:

Strips Type = GI (Galvanized Iron)

Duct Type = Flat Duct (FA) , Round Duct (MA)

Strip Thickness = 0.3mm

FA Duct Dimension = 5s & 4s (80 x 20mm)

3s & 2s (60 x 20mm)

MA Duct Diameter = 68mm to 135mm



GI - Duct:





3s & 2s (60 x 20mm)




GI - Duct:





3s & 2s (60 x 20mm)




Anchorage:

Flat Anchorage (FA):

Multi Anchorage (MA):



Anchorage:





Anchorage:





Wedges:

Tendon Sample:



Wedges:

Tendon Sample:



Wedges:

Tendon Sample:



T – 10 Hydraulic Jack:

T – 25 Hydraulic Jack & Pump











Grout Pump:



Grout Pump:



Grout Pump:



ANNEXURE – 3

CHECK LIST



ANNEXURE – 3

CHECK LIST



ANNEXURE – 3

CHECK LIST



SF ENGINEERING SYSTEMS (INDIA) PVT. LTD.(Reliable Partner in Specialized Engineering )

CHECKLIST FOR INSTALLATIONPROJECT NAME DATE

LOCATION/FLOOR DRAWINGNO

GRID NO /POUR DRAWINGREV

Tendon ID :-

S.NO ELEMENTS TO BE CHECKED OK NOTOK REMARKS

1 Placement of Type of Duct

2 Placement of Numbers of Tendons

3 Placement of Tendons Spacing

4 Correct Numbers of strand Installation within duct

5 Length of strands are enough for stressing

6 Position and correct type of casting at live end

7 Position and correct type of dead end

8 Profile of Tendons at supports points

9 Placement of correct type and no of bursting steel

10 Placement of correct spacing links

11 Ensure all grout ports are provided

Comments : (RCC)

SFEC REPRESENTATIVE CONTRACTOR REPRESENTATIVE CLIENT REPRESENTATIVENAME :- NAME :- NAME :-

DESIGNATION :- DESIGNATION :- DESIGNATION :-

DATE :- DATE :- DATE :-

SIGN :- SIGN :- SIGN :-







Tendon ID :-













Comments : (RCC)











Tendon ID :-













Comments : (RCC)








CHECKLIST FOR STRESSING

PROJECT NAME DATE



Tendon ID :-


1 Preparation For Stressing

2 Fixing of correct Type of Anchorages

3 Fixing of correct Type of Wedges

4 Applied forces for 75% UTS

5 Elongation to be Measured and For the limit

6 Cut off the Excess Stressing strands.

Comments :

SFEC REPRESENTATIVE CONTRACTOR REPRESENTATIVE CLIENT REPRESENTATIVE

NAME :- NAME :- NAME :-


DATE :- DATE :- DATE :-SIGN :- SIGN :- SIGN :-





PROJECT NAME DATE



Tendon ID :-








Comments :









PROJECT NAME DATE



Tendon ID :-








Comments :








CHECKLIST FOR GROUTING

PROJECT NAME DATE



Tendon ID :-


1 Filling of the recess pockets left out for stressing

2 W/c ratio Maintained as per the methodology

3 Cement and Admixtures following as per the methodology

4 1st Stage of Tendon flushing with water

5 2nd Stage of Tendon filled with Grout

6 Grouting Completed after cut of the Excess hose

Comments :










PROJECT NAME DATE



Tendon ID :-








Comments :










PROJECT NAME DATE



Tendon ID :-








Comments :








ANNEXURE – 4

ADMIXTURE



ANNEXURE – 4

ADMIXTURE



ANNEXURE – 4

ADMIXTURE

C

ebex

100

Cebex 100* (Formerly Conbex 100)

Plasticised expanding grout admixture

Uses

Cebex 100 is an admixture for cementitious grouts where a reduced water/cement ratio and positive expansion is required. Applications include bed grouting, duct grouting, non-shrink infilling and jointing.

Advantages

! Gaseous expansion system compensates for plastic

shrinkage and sett lement in properly designed cementitious grout.

! Reduced water/cement ratio mixes in the grout mix ensures low permeability and long term durability in service.

! Gives high grout fluidity with low water/cement ratio, thus making placement or injection of the grout easy.

! No metallic iron content to corrode and cause staining or deterioration due to rust expansion in the grout.

! Composition allows high early strength development in grouts, without the use of chlorides.

Standards compliance

Cebex 100 is a suitable pre-stressing grout admixture when complying with BS 8110 Part 1, 1985, section 8.9.4.6.

Description

Cebex 100 is supplied as a powder admixture. The material is a combination of a plasticising agent and a gas producing expansion medium. The plasticising agent allows the use of a reduced water/cement ratio with consequent increased strengths and durability. The expansive medium counteracts the natural settlement and plastic shrinkage of the grout and aids stability and cohesion.

Sufficient restrained expansion is developed to ensure a high degree of interfacial contact.

Specification

Performance specification

All grouting (specify details and areas of application) must be carried out with a cement based grout incorporating a plasticised, expanding powder admixture. The admixture must be iron-free and chloride-free and shall be added to the grout in the proportions 225 g of admixture per 50 kg of cement. The admixture shall provide an expansion of up to 4% in the plastic grout, by means of a gaseous system. The admixture must be stored, handled and mixed strictly in accordance with the manufacturer's instructions.

Supplier specification All grouting (specify details and areas of application) must be carried out using a cement based grout, incorporating Cebex 100 manufactured by Fosroc and applied strictly in accordance with the manufacturer's technical data sheet.

Properties Chloride content : Nil to BS 5075 Compressive strength : The plasticising action of

Cebex 100 allows reduction of the water/cement ratio of cementitious grouts whilst maintaining flow properties. This gives improvement in strength and long term durability when cured under

restraint. Setting times : Cebex 100 does not

significantly affect the setting times of cement based grouts.

Expansion characteristics: The controlled positive expansion in unset grouts incorporating Cebex 100 overcomes plastic settlement when measured in accordance with ASTM C827. An unrestrained expansion of

up to 4% is typical. Time for expansion : 15 minutes - 2 hours.

Temperatures above 20°C may slightly reduce these

times. Compatibility : Cebex 100 is compatible

with all types of Portland cement. Cebex 100 may be used in mixes containing certain other Fosroc admixtures. Consult Fosroc

for further information.

Instructions for use

Mixing

For best results Fosroc MR3 mixer must be used. For quantities up to 50 kg a slow speed drill fitted with a high shear paddle is suitable. Larger quantities will require a high shear vane mixer.

It is essential that machine mixing capacity and labour availability is adequate to enable the grouting operation to be carried out continuously. This may require the use of a holding tank with provision for gentle agitation to maintain fluidity.

The selected water content should be accurately measured into the mixer. Slowly add the cement (and sand if required) and Cebex 100. Mix continuously for 5 minutes, making sure that a smooth even consistency is obtained.

Application

Areas to be grouted should be prepared to ensure substrates are clean, sound, and then pre-wetted. The unrestrained surface area of the grout must be kept to a minimum. Place the grout within 20 minutes of mixing to gain the full benefit of the expansion process. Adopt usual placing or pumping procedures ensuring a continuous operation.

Curing

On completion of the grouting operation, any exposed areas which are not to be cut back should be thoroughly cured by means of water application, Concure* curing membrane or wet hessian.

Cleaning

Grouts mixed with Cebex 100 should be removed from tools and equipment with clean water immediately after use. Remove cured material mechanically or with Fosroc Acid Etch.

Limitations

Cebex 100 is not compatible with High Alumina Cement.

Estimating Supply Cebex 100 : 5 kg packs & 225 g tins Dosage OPC Concreting Water Conbex Approx sand 100 yield 50 kg - 20-22 litres 225 g 36 litres 50 kg 50 kg 22-24 litres 225 g 57 litres Note: For grout, mortar or concrete mixes with an aggregate/

cement ratio more than 1, use 4x225 g units or 900 g of Cebex 100 per 100 kg of cement.

Effects of overdosing Overdosing of Cebex 100 increases expansion and may cause frothing.

Storage Cebex 100 has a shelf life of 12 months if kept in a dry store in its original packaging. High temperature and humidity storage may reduce this period.

Precautions Health and safety Cebex 100 is of low hazard. Contact with the skin and eyes, or inhalation of dust should be avoided. Wear suitable protective clothing, gloves, eye/ face protection and dust mask. After contact with skin, wash off with clean water. In case of contact with eyes, rinse immediately with plenty of water and seek medical attention. For further information see Product Material Safety Data sheet. * Denotes the trademark of Fosroc International Limited † See separate data sheet

Al Gurg Fosroc LLC REGIONAL SALES OFFICES IN :

P. O. Box 657 Dubai United Arab Emirates

TEL : (04) 858606 FAX : (04) 859649

DUBAI Al Gurg Fosroc TEL : 858787 FAX : 852023

ABU DHABI Al Gurg Fosroc TEL : 731779 FAX : 731449

BAHRAIN YBA Kanoo TEL : 735454 FAX : 732828

KUWAIT Boodai TEL : 4817618 FAX : 4832124

OMAN GETCO TEL : 7715080 FAX : 7717554

QATAR Tadmur TEL : 4413628 FAX : 4440812

Important note

Fosroc products are guaranteed against defective materials and manufacture and are sold subject to its standard terms and conditions of sale, copies of which may be obtained on request. Whilst Fosroc endeavours to ensure that the technical information on this data sheet is correct at the time of printing, it is the customer’s responsibility to satisfy himself, by checking with the company that this information is still current at the time of use, that the product is suitable for the intended application, and that the actual conditions of use are in accordance with those recommended. Because Fosroc has no control over the conditions of use of its products, all recommendations or suggestions regarding the use of these products are made without guarantee.

www.fosrocgulf.com UAE/0321/00/A



ANNEXURE – 5

SAFETY



ANNEXURE – 5

SAFETY



ANNEXURE – 5

SAFETY



Safety Work Procedures for Post Tensioning Work

1. Installation of Tendon Operations:

Lifting of Post Tensioning Materials

Lifting operation to comply with Operation Crane regulations

Ensure Lifting Supervisors / Signal Man are qualified.

To explain about the work process to the workers dealing with

lifting work before the work starts.

Installation of Strand Dispenser

Ensure the dispenser is sufficiently stable to prevent from collapse.

Ensure no personnel standing in front of dispenser when uncoiling

strand.

Use safety gloves when working.

Usage of electrical equipments

Ensure proper industrial socket, plug and connectors are used

before starting of work.

The wires should be raised above ground level.

Proper shelter should be provided for all electrical components at

wet weather conditions.

Use safety gloves and shoes at time of work.

Cutting of PT Strand

Cutting machine should have a safety guard covered to it before

starting the work.

Use gloves and safety goggles at time of work.













strand.











starting the work.














strand.











starting the work.




Working near edge of the building

Workers have to briefed for working on heights before

commencing the work.

Safety belt connected to jacket has to be anchored to a permanent

structure, if the workers are working at outer periphery of the

building.

Provision of effective barricades.

2. Stressing of Tendon Operations:

Setting up of Stressing Equipment

Only trained personnel are allowed to install and operate the

equipment.

Ensure the jack and pressure cage are calibrated.

Stressing area precautions

Stressing area has to be barricaded to avoid other workers entering

the zone till completion of stressing activity.

No workers shall stand behind or at the face of the jack during

stressing.

There should be enough space between the jack and worker who is

handling it at time of stressing the tendons.



building.








building.





equipment.






stressing.





building.








building.





equipment.






stressing.





building.



3. Grouting of Tendon Operations:

Lifting of cement bags

Lifting operations to comply with crane regulations.

Lifting done manually the worker has to wear safety helmet, gloves

and goggles along with nose mask.

To explain about the work process to the workers dealing with lifting

work before work starts.






building.


Grouting area precautions

Ensure the workers are wearing safety helmet, gloves and goggles

along with nose mask.

Proper hose cleaning should be done after the completion of stressing

activity.

Safe method to check on pressure grout hose to be briefed to the

workers.

Ensure proper patching is done before the commencement of grouting

activity.

Ensure all the tendons is been grouted individually.















building.






activity.


workers.


activity.
















building.






activity.


workers.


activity.




ANNEXURE – 6

Quality Assurance Policy (QAP)



ANNEXURE – 6




ANNEXURE – 6




In House Quality Assurance Policy for SF Systems

Note: System acceptance test will be conducted from any of the reputed

lab based on the requirement and the same will be done once in a

year.

Performance test - Material Test Certificate (MTC) will be issued for

every lot to be used at site.

SystemAcceptance Test

AnchorageEfficiency

TestLoad

Transfer Test






year.



FIPRecommentations

LoadTransfer Test

Performance Test(Materials)

Anchorage Sheathing






year.



Performance Test(Materials)

Strand



System Acceptance Test:

Anchorage Efficiency Test

Objective of the test:

This test is conducted to check and verify the performance of the

anchorage assembly and to determine any decrease in breaking load of the

Pre – Stressing steal (Strands) due to the influence of the anchorage, and to

observe the elongation and behavior of the wedges.

Test Remarks:

The test will be conducted at any of the reputed lab based on the

requirement which satisfy FIP recommendations.

Frequency:

The entire test is related to SF system policy and will be conducted

once in a year.

Load Transfer Test


This test is conducted to verify the transfer of the pre stressing force

from the mechanical anchorage and its competency to the concrete without

any failure in the anchorage assembly.

Test Remarks:



Frequency:


once in a year.










Test Remarks:



Frequency:


once in a year.

Load Transfer Test





Test Remarks:



Frequency:


once in a year.










Test Remarks:



Frequency:


once in a year.

Load Transfer Test





Test Remarks:



Frequency:


once in a year.



Quality Assurance Policy at Site

Sl.

NoWork Sequence Formats Objective Field Inspection

1Monitoring of work prior

to concreting

Checklist on

completion of

laying

To check profile ,

spacing and

number of strands

per tendon

Shop drawing

prepared based on

the design

requirement will

serve as basis

2Post Concreting

Inspection

Concrete cube

strength

minimum

27N/mm2

To check concrete

is ready to

withstand Pre

Stressing Force

Theoretical tendon

elongation report

submission for every

pour/slab

3At the time of stressing

activity

Stressing records

and elongation

reports has to be

prepared

To check the

satisfactory

performance of

the stressing

carried

On submission of

stressing record , De

– Shuttering

operations can be

carried out

4At the time of grouting

activity

Field Test such

as Cube Test and

Viscosity Test

To ensure the

flow character of

the grout and to

check the

strength of the

grout

Viscosity test and

compressive

strength are

conducted before

grouting and this

test is truly based

on requirement of

the clients.




Sl.



to concreting

Checklist on

completion of

laying

To check profile ,

spacing and

number of strands

per tendon

Shop drawing

prepared based on

the design

requirement will

serve as basis

2Post Concreting

Inspection

Concrete cube

strength

minimum

27N/mm2

To check concrete

is ready to

withstand Pre

Stressing Force

Theoretical tendon

elongation report


pour/slab


activity

Stressing records

and elongation

reports has to be

prepared

To check the

satisfactory

performance of

the stressing

carried

On submission of


– Shuttering

operations can be

carried out


activity

Field Test such

as Cube Test and

Viscosity Test

To ensure the

flow character of

the grout and to

check the

strength of the

grout

Viscosity test and

compressive

strength are

conducted before

grouting and this

test is truly based

on requirement of

the clients.




Sl.



to concreting

Checklist on

completion of

laying

To check profile ,

spacing and

number of strands

per tendon

Shop drawing

prepared based on

the design

requirement will

serve as basis

2Post Concreting

Inspection

Concrete cube

strength

minimum

27N/mm2

To check concrete

is ready to

withstand Pre

Stressing Force

Theoretical tendon

elongation report


pour/slab


activity

Stressing records

and elongation

reports has to be

prepared

To check the

satisfactory

performance of

the stressing

carried

On submission of


– Shuttering

operations can be

carried out


activity

Field Test such

as Cube Test and

Viscosity Test

To ensure the

flow character of

the grout and to

check the

strength of the

grout

Viscosity test and

compressive

strength are

conducted before

grouting and this

test is truly based

on requirement of

the clients.



HEAD OFFICE:SF ENGINEERING SYSTEMS (INDIA) PVT. LTD.

(Reliable Partner in Specialized Engineering)

No.118, 13th Cross Street, Sri Sai Nagar,

Thoraipakkam, Chennai – 600097

M - +91 9840066239, + 91 9551635559, +91 8220373680

E – [email protected] , [email protected] , [email protected]

REGIONAL OFFICE:DEHRADUN NEW DELHI

2nd Floor, Tilak Plaza, Tilak Road, 220, Ground Floor, Arjun Nagar

Dehradun, Uttrakhand – 248001. Sufdurjung Enclave, New Delhi-

M - +91 9045089020 New Delhi- 110029

E – [email protected] E – [email protected]

PUNE BANGALORE

F – 133, Ashok Mall, 27/53/3, Srinivasa Nilaya,7thMain

Opp to Sun & Sand Hotel, Bundgarden Road J.P Nagar, 1st Phase, Sarakki

Pune – 411001 Kanakpura, Karnataka - 560078

M – 9850431195 M - 8600902222

E – [email protected] E - [email protected]

COIMBATORE

No.30, 1st Floor, Shanthi Nagar,

Vilankuruchi Main Road, Cheran Maa Nagar

Coimbatore – 641035

M – 9994247766

E – [email protected]







M - +91 9840066239, + 91 9551635559, +91 8220373680





M - +91 9045089020 New Delhi- 110029


PUNE BANGALORE




M – 9850431195 M - 8600902222


COIMBATORE




M – 9994247766








M - +91 9840066239, + 91 9551635559, +91 8220373680





M - +91 9045089020 New Delhi- 110029


PUNE BANGALORE




M – 9850431195 M - 8600902222


COIMBATORE




M – 9994247766




SF Engineering Systems (INDIA) Private Limited


ASSURING OUR BEST SERVICE & SUPPORT AT ALL TIMES











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